D-Band Antenna-Filter Integration Using Metal 3D Printing

Low-cost fabrication of D band components is still challenging because of the small feature size of the design parameters. This paper introduces current 3D printing technologies that can be used to produce metallic waveguide-based components. In particular, metal binder jetting (MBJ) is a support-free printing technique suitable for printing complex structures. This paper aims to discuss D band antenna-filter integration by applying the MBJ process. The manufacturing strategy is applied to the design and optimization of an asymmetric iris filter which is later integrated with a resonant cavity antenna. The simulation results show that the proposed antenna-filter module has a three-order filtering performance with a maximum gain of 16.5 dBi.